Custom Poly Mailers

Custom Printed Poly Mailers with Logo, Self-Seal Strip, and Tear Strip

What custom poly mailers are used for

A poly mailer is a lightweight shipping bag made from plastic film, with a self-seal adhesive strip at the top. The seller packs the item, presses the strip closed, and ships the bag in the mail. Brands use custom poly mailers for clothes, swimwear, accessories, books, beauty kits, and other soft goods that do not need a rigid box. A mailer weighs less than a box, takes little storage space, and costs less to ship. A printed mailer also makes the package look like yours when it arrives at the customer's door, before anyone opens it.

Sizes and how to measure

Mailer size is written as width x height, and the flap adds more length. To choose a size, fold or pack your item the way you plan to ship it, measure its width and height, and add room so it slides in easily. A mailer of about 6 in x 9 in suits small accessories and jewelry, and about 10 in x 13 in suits a folded t-shirt or a small kit. A mailer of about 14.5 in x 19 in suits hoodies and bulky clothes, and about 19 in x 24 in suits large garments and bundles. Tell us your item and how you fold it, and we suggest the right size.

Example sizes (approximate and for reference only; we confirm the exact size before you order):

• Small: about 6 in x 9 in
• Medium: about 10 in x 13 in
• Large: about 14.5 in x 19 in
• Extra large: about 19 in x 24 in

Film, color, and bubble lining

Poly mailers are made from layers of plastic film, and the film is usually opaque, so the contents stay private. Custom poly bag mailers come in white, black, silver, and many colors, and the inside can be a different color so no one can see through the bag. A thicker film is tougher and resists tears, and a thinner film is lighter and costs less. Custom poly bubble mailers have a bubble layer inside that cushions the item, and they suit fragile items such as cosmetics, jars, and electronics. Mailers are water resistant, but they are not a guarantee against damage, so choose bubble lined film for fragile items. A self-seal strip and a tear strip make the bag easy to close and open.

Printing and finishing

Custom printed poly mailers can carry your logo and design in one or more colors. Because a mailer is large, the print can be a single logo, a pattern, or a design that covers the whole bag. Custom poly mailers with logo look best with bold colors and simple shapes. White ink stands out on black and colored film, and a dark ink stands out on white film. Customized poly mailers can carry a thank-you message, a care note, or a social handle on the back. Keep the print away from the seal strip, and leave a small area for a shipping label.

Labeling and shipping notes

A mailer carries a shipping label, so plan a clear area for it. Plastic bags can also need a warning about suffocation risk for children, and you should check what applies to your product and your sizes. If your mailer holds a product for sale, you are responsible for any other text that the law requires for your product. We do not write or check label text or claims.

Orders from 5,000 units

Orders start at 5,000 units, which suits a brand that ships orders every week. Custom poly mailers wholesale orders cost less per mailer than small runs, and they can be planned in several sizes and repeated as order volume grows. A run of this size is also a good time to plan your design carefully, so every package looks the same. Share your expected yearly volume during the free consultation and we plan around it. Mailers arrive flat and ready to pack.

Artwork and dieline

We send a free dieline that shows the print area, the seal strip, and the tear strip of your mailer, so you can see where your artwork goes and where it should stay clear. Supply artwork as a vector AI or PDF file with fonts outlined and images at 300 DPI in CMYK. If you have no artwork yet, free design support and a free consultation are included, and our team can help lay out the logo and the text from your brand colors. You review and approve the artwork before production starts.

How to order custom poly mailers

1. Choose your mailer size, film color, and plain or bubble lined.
2. Order a $59 sample kit if you want to feel the film and seal first. The $59 is credited toward your order total.
3. Send your quantity, starting at 5,000 units.
4. Receive your free dieline and add your artwork, or ask for help.
5. Review and approve the artwork.
6. Production takes 6 to 8 business days after artwork approval, and your order ships free to one U.S. address.

The final price depends on mailer size, film thickness, color, printing, bubble lining, and quantity.

What comes with every order

• Free shipping to one U.S. address
• Free thank-you cards equal to the units ordered
• Free design support, free dieline, and free consultation
• Orders start at 5,000 units
• Eco-friendly materials sourced from certified suppliers